Construction surfacing system



Feb. 27, 1940. H, P, FOR@ 2,191,461

I CONSTRUTION SURFACING SYSTEM y Filed Sept.. 5, 1936 2 Sheets-Sheet 2 ATTORNEY Patented Feb. 194i) f. Y y 2,191,461 ,y Y ooNsTaUoTloN sUR'FAoING SYSTEM Harold P; Ford, Seattle, IWash. 'Application septembeps, 193s, serial No. 99,616

' 5 Claims.- lol;`- 12j-416) My inventionrelatesto a construction sur-f. facing system, and the-generalobject ofmyine vention is to providethin sheet, lightweight, waterproof, weatherproof, kfire-resistant, beautifuL fpermanent and low-cost buildingsurfacing for;A

roofs, walls, and-other parts of existing orv new constructiom of wood, lsteel or other materials.`

Present surfacing'systems for constructonare all subject to one or more of the following disflllY advantages and objections: high first costato-,-Y gether with high cost .of maintenance; rapid depreciation in value, making lfinancing and refinancing diliicult; constituteiire hazards, and,

permit large losses of 'life andproperty; not' Ywa-Y 151 tertight, resulting in decaycorrosion and-'damp age; are deficient in regardto security andpermanence; lack enduring beauty andA attractive; ness.

v faces exposed to the weather, is of great `impor,

tance. Much could be written about the unsatisf,

factory building surfacing methods of thepast, and of the present time. KThese methods Aare wasteful in the extreme,lof both 'materials and labor, largelybecause oftheir lack of perma-v hence. Financing andv refinancing of, construe? vtion is far more difficult thanneedbe, becase'-fof the rapid depreciation lin valuefofl building conf.

' struction; because of the lack ofenduring at tractiveness of: buildings;A because of the lack of liveV public interestin ourarchaic and faulty building methods; and because Io fk the :lack-of financial faith in these methods.

lvMy invention 'overcomes theobjectionabl'e'qfear,

tures hereinb'efore set forth, bylprovidg vathix'isheet plaster base' for surfacing of `construction,` which has as its base a thin watertightI membrane of metal or metal alloy; which vlfiasa Acoatingof weatherproof adhesive `material""toffprotectjthis o membrane, and tosecurely bind to. thisjmetal membrane a weatherproof aggregate surface;v` which further has the aggregate particlespressed or rolled into' the sheet,l to vcausef'pitting' or rougheningr of the thin metal membrane, tese, 445 cure excellent bonding of the `aggregate surface'y to the membrane, andto provide 'for` expansion and contractionrin the membrane; or' whichfurther has a heat treatment to increase settingandA bonding of the adhesive material;` or whichl further has a coating of grout consisting of 4sand f and cement bonded to the aggregate surface,

for'further protecting and weatherproongboth-- the adhesive material and the metal membrane.

, and to furnish a surface capable of permanently bonding ona beautiful plaster or stucco coat.

The surfacingl ofbuildings, especially onthose v metal membrane, sheets.

Watertightness and permanence. are' insured bythe metal vmembrane. and yby the multiple pro'- tection 'of same. The coating of cement plaster, together with the mineral aggregate surface, ef-

fectively protectthe bonding or adhesive'coat- 5 f ing, and, together with this weatherproof adr hesive coating, protect the metal membrane. Bonding is further secured by rolling or press' ingxto cause roughness or pitting of thethin lmetal membrane.l This ample protection in--lllzsures'durability which is essentially permanent. Weathering agencies cannot penetrate or damage vthis watertight durable` sheet; andocannot damage anyyconstruction work surfaced by same.`

Jointsare, to a large extent, avoided, becauser 15 ,a

of the large area covered by each sheet. Where joints are used, they are of a watertight and permanent nature. ,Alvarietyof joints is possible,\` because of Athe thinness of the sheets. Joints are sealedbycement or weatherproof adhesive, to 20 bond. the rough lappingedges together, and arel further secured byv metal ties. y l

:Enduring beauty of construction is made possibleat low cost. This material isV adaptable to all angles and. curvatures of surface, vertical or 2,5.

horizontal, outside or'inside.l `It is ideal to receive, and to. permanently bond, beautiful coats of rcement plaster or stucco in a limitless number of nishes and color combinations. These finish coats will be permanently bonded on be- 30 cause'of theweather resisting qualities of .ther

' mineral aggregates and cement; because of the excellent bondingof the weatherproof aggregates 1A.

vto the watertight metal membrane by the weathf y erproof adhesive; and because of the ample proal1- tection of both the weatherproof bonding maf.

-terial and the metal membrane.

Theabove'mentioned general objects of my l invention, together withv others inherent in same,

are lattained inthe manner illustrated in the 40 following drawings, the same being preferred exemplary forms of my invention, thruout which drawings like reference numerals indicate like partsf` Fig. 1 is a vertical section thru a plant 'unit 45 used for applying a weatherproof adhesive "coating and a weatherproof aggregate surface to thin Figs. 23 and 4 are 'typical sections, in any direction, somewhat magnified, showing yseveral stages in the process of manufacture 'ofwatertight plasterbase thin-sheets.vvv o v Fig.- 5 isa typical section, in any direction, at 1 approximately full size, of a plasterbase v`sheet at 55 eral 'grains which fall between successive sheets.

In Fig.` 2 I show a thin metal sheet .with a coating of `weatherproof adhesive'fto; bond'to the thinsheet particles I3 ofne weatherproof mineral, aggregates, of varying,.size. c After the adhesive hardens orsets thissheet could be used f as a watertight weatherproof plasterbase.'` Howeverjitispreferable tofget more positivebonding of the aggregate to the thin metal' sheet.- By

rolling the sheet shown in Fig. 2, under high unit pressure, we get fthesheet shown 'in Fig.'3 in l excellentfproduct is the result; namely a thin which pitting or IindentingfCif-the thin metal f vides for expansionand contractionv in the metal f sheet. It is preferred to apply pressure to the sheets 4in multiple, as by applying highv unit pressure 'to'stacks II, shown in Fig. 1. In this manner deformation of the thin metal sheet-is produced similar to that shown 'in Fig. 3, because of high pressureapplied tok thestack in which thin 'metal sheets are alternately situated ybetwee'ntrough layers of hard mineral'faggregates.'

'Ihe sheetscan. remainin stack, subject to more orle'ss pressure, until the adhesive bonding coatinghardens or sets. In this 'mannen `simple plant Ais possible with large capacityjandv an pittedfwatertightmetal membrane coated 'and protected by ya weatherproof adhesive. coating which securely bonds to the pitted membrane a rough 'surface of iine weatherproof mineral aggregate.

' The aggregates I3 used may be particlesl of natural rock or minerals, or .may be particles of other weatherproof solids; they [may be more 'u or less vuniform in size or of varying sizes; they rnayc'o'nsist of rounded grains, fas fine or coarse sands," or may consist 'of rough particles as crushedrock."`- Aggregates of larger sizes than thosemshown'may be used; however, larger ag-v gregate's will cause thicker and heavier sheets, andwill not, permitas secure bonding 4to the metal'membrane, as will the finer aggregates. In case the weatherproof adhesive coating is applied hotto .the.,thin sheets, itis preferable to' have themineral aggregates y lf3 ina heatedcondition i when applied.v

-V.After the-mineral aggregate-surface hasbeen bonded securely `to the thin metal .membrane by, the weatherproof adhesive coating, and after the adhesive has hardened or set, the 'resulting thinsheetsmaybeused directly as a thin sheet surfacing material or plasterbase. .Howeven it is preferred to apply athin coatingof weatherproof ne sand and cement mixture, as shown at I1 in Fig. 4. This thin coating fills the spaces between the adhering aggregate grains prevents same from being abraded; and furnishes an excellent surface for bonding a plastercoat. After vthis thin sand-cement coating has set, sheets are ready for use as a plasterbase.

A heat treatment may be used, after pressing the thin sheets, to eliminate any'light volatile materials from the adhesive coating, and to cause the adhesive material to harden `and to adhere more rmly to the metal membrane; or to -bond the weatherproof aggregates to the metal `membrane by a baked-on adhesive coating.

, approximatelyrfull .lsize,MT ready for use.

In-'FigL 5 plasterbasefsheets I 8 are shown, .at In the following-V described methods of surfacingl (with plasterbase sheets, same arereferred to as" I8.v

Similar .uses are .possiblel'fori'sheets which have not receivedzthe complete series of ,treatments asdescribed for-.sheetseI.' v

' In Fig.l 6 iI- showplasterbase sheets I8 applied as af'weatherproof watertight surface overy eX- istingior new woodlwall or -roof construction I9, and secured to same-'bydurable nails, drive screws orl other metal'ties 20' with a plastercoat` 21 of cement plaster or stucco lapplied on Jthe .plasterhase.l f If fdesired; tha-finish plaster coaty mayv bebutt-lendedas shown at 22 and marked like shingles',- shakes,' slates -or tiles.r Plasterbase sheets? I8 couldbe 'applied-f lapped like shingles or-ti1es,if fdesirediv f It is apparent how thereis no `waste `of plastering materials when plastering on these plasterbase sheets. Moreover, the' operation of applying plastercoat to these sheets is very easy, and

highly skilled workmen'aie not required. A thin priming coat isl recommended prior to finish plaster coat. V

Whenplasterbase isheets I 8- are 4secured to other-'constructionby nails or drive screws'Z, samer'should preferablyyhave points dipped in weatherproof ,ja'dhesive material `before driving, to 'make nail"l1 0le`s "`watertight,v to` protect nail or drive screw from' corrosion, and lto holdy nail ordrive screw securely in place.`

In Fig; 7"I' show plasterbasesheets I8 vapplied as ka watertight `v veatlierproo iing surface over steel frame wall andy roofconstruction 23 and,

secured-tol same by metal ties 24, with a plaster-v coat v2l of'cementlplaster'orstucco. Figf '7.also shows the usejofv lapped joints, `thinly cemented, together withfmetalties'25".

. ,In 8` I'showf'plasterbase sheets I8 applied as a form` material," between which, on which or against which concrete 26 ispoured. Sheets" I8 serve ,as a watertight form surfaceduring ythe `pouringoperationandbondto the co-ncrete as `it hardens or sets.' Plasterbase sheets I8ijalso give' a secure 'bond totheplastered surface 2 I. Inl this application offplasterbase sheets I8, the concrete may consist of afcemented mixture y'of porous lightweight aggregates, in which case the combination will` consist of` a' beautiful plastered surface Z'Ibonded'to awatertight metal membrane plasterbase I8, 'whicl'i is bonded to a porous heatfinsulating concrete 26.'- Fig. 7 8 valso shows the',use.o fj plasterbase. sheets I8 as la watertight `roof or' oor surface. above concrete, being lcerruented down, andserving to bond a finished top surface. .v Fig'.l 8 also shows the .use of sheets I8`fas afwatertightv membrane vwithin a massof concrete, and bonded on both sides tothe concrete.

In Fig. 9 I show sheets I8 applied as a plasterbase for interior or exterior surfaces, including floors, walls, ceilings and coves. In Fig. `10 I show sheets I8 appliedy as a plasterbase for interior or exterior convex or concavev surfaces, wherein this material serves as a watertight base for attaching plastered surfaces 2|., This thinsheet plasterbase is specially suited for various irregular plastered surfaces.

' InFig. 11 I show sheets .I8 applied as a Waterconstruction 21, wherein sheets I8 form a water#- tight surface over'or against the porous blocks 21, and are secured to blocks by metal ties 28 or to framework Zasupporting the blocks, by metal ties 3D; thus forming a watertight metal membrane plasterbase inv combination with a heatinsulating block backing, together with a plaster surface 2| permanently bonded to plasterbase.

In Fig. 12 I show sheets `.I3 applied as a surfacing over a framework of wood or metal, 3| and 32 respectively, with space between plasterbase surfaces packed or filled with lightweight porous loose mineral filler 33, thus forming a Watertight metal membrane plasterbase in combination withloose heat-insulating backing.

In Fig. 13 I show sheets I8 applied as a watertight plasterbase or coping Aover or against Waterabsorbing brick or masonry surfaces 34, with sheets I8 secured to same by metal ties 35, with plastered surfaces 2|. A similar use is the application of sheets I8 over thin-walled hollow block construction.

In Fig. 14 I show the application of sheets I8 as a watertight and protective encasement of wood 36 or steel 31 posts, columns, beams, and other structural members, with plaster coat 2|.

In Fig. 15 I show a section of a structural angle 38 and of a thoroughly dry wood member 39, coated with weatherproof adhesive material, preferably emulsied bituminous material, by which a roughened surface of fine mineral aggregate 46 is caused to adhere to Vthe structural member to produce a surface suitable vfor bonding plastercoat 2|.

In Fig. 16 I show a preferred type of lap joint of sheets I8, wherein sheets I8 are applied against a wood surface 4I; wherein sheets I8 are lapped as shown, together with cementing or adhesive material 42 applied., between the sheets in the lap; wherein a largewire or small rod 43 extends continuously along the lapped joint and situated between the surface 4I and the underlying lapping edge, together with nails or drive screws 20 along edges of lapping sheets, each side of rod 43, thus to produce acrimping effect in the lapping edges, and positive sealing of the cemented joints.

In Fig. 17 I show the application of sheets I8 to the manufacture of` posts,` by bending sheets around a form, together with a plaster coat 2|. The center may be lled `with concrete 26.

In Figs. 18 and 19 I show a type of rolls for producing pitting or indenting of a thin metal membrane, wherein thinsheets I are passed between two rolls, as shown by arrows. Roll 44 is a hard surface roll having projections and depressions on its face. Roll 45 has a yielding' surface, as of hard rubber. As a result of passing between rolls 44 and 45, thin vsheet I is given ay pitted surface as shown at 46. In Figs. 20 and 21 I show an alternate method of producing pitted sheets 46, in which both rolls have hard faces together with intermeshing projections and de, pressions on faces.

, In Fig. 22 I show pitted sheets 46 `coated with fine weatherproof aggregate, particles I3 bonded to the pitted sheetsl 46 bya weatherproof adhe-` sive coating, to form a watertight plasterbase.

In Fig. 23 I show a thin metal sheet I bonded on both sides to fine weatherproof aggregate particles I3 by a weatherproofv adhesive material. By pressing this sheet between hard surfaces a thin watertight plasterbase is formed, as s hown in Fig. 24, wherein some of the aggregate particles are pushed into the thin metal membrane to form pitting or cupping of same, and thus. the aggregates have large area of contact with, and secure bond to, the membrane.

Obviously, changes may be made inthe form, dimensions and arrangement of the parts of my invention, without departing from the principle thereof; the above setting forth only a preferred form of embodiment.

I claim: A y

1. A new article of manufacture comprising a thin metallic membrane having irregular indentations disposed therein, an adhesive coating afxed to one side of the membrane, and a layer of aggregate bonded to themembrane by the adhesive coating, individual particles of the aggregatebeingintimately cupped within the indentations'.

2. A device of the class described comprising a thin membrane, a plurality of indentations disposed upon the membrane, a primary coatingof adhesive material spread upon the membrane, and a secondary coating of aggregate spread upon the coating of adhesive material, individual .par-

ticles of said aggregate being cuppedlwithin'sad indentations. v

3. A device of the class described comprising a metallic membrane, a plurality of indentations disposed upon the membrane, a primary coatingv of cementitious material spread upon themern'-` brane, and a secondary coating of aggregate material disposed upon the primary coating, of cementitious material, particles of said aggref' gate being recessed within saidindentations.

4. A plasterbase comprising an indented metallic membrane having a foraminated cementitious coating affixed thereto, and particles of aggregate recessed within the indentations of the membrane' and piercing vthe foramina of the coating.

5. A' plasterbase comprising a thin metallic membrane having indentations disposed therein, a primary coating of cementitious material disposed upon the membrane, and a secondary coating `of aggregate material intimately disposed upon the primary coating and matrixed within said indentations".

l HAROLD P. FORD.

Feb. 27, 1940. H. GIDDxNGs CORRUGATED ICE COMPARTMENT 3 Sheets-Sheet 1 Filed March 26, 1938 INVENTOR v ATTORNEYS Mv; lBY E 

